WO2022138052A1

WO2022138052A1 - Decorative film for insert formation, manufacturing method of decorative film for insert formation, and manufacturing method of resin molded product

Info

Publication number: WO2022138052A1
Application number: PCT/JP2021/044317
Authority: WO
Inventors: 充康奥田; 裕介上野; 眞太郎桑坂
Original assignee: Ｎｉｓｓｈａ株式会社
Priority date: 2020-12-21
Filing date: 2021-12-02
Publication date: 2022-06-30
Also published as: DE112021006576T5; CN116635203A; JP2022097950A; US20230405984A1; JP7158458B2; US11872789B2

Abstract

[Problem] To provide a decorative film for insert formation which has high dimensional accuracy of a gravure printed design layer and a light transmission design layer, and which can suppress the flow of ink in gravure printing of a polycarbonate resin molded product. [Solution] A multilayer film 20, which transmits visible light, comprises a first polycarbonate resin film 22 arranged between a first acrylic resin layer 21 and a second acrylic resin layer 23 and formed from a polycarbonate-base resin. A gravure printing layer 30 has a design layer 31 in which a design is rendered with gravure printing. A first backer film 40 is formed from an ABS-base resin that transmits visible light. A second backer film 50 comprises a second polycarbonate resin layer 52 arranged between a third acrylic resin layer 51 and a fourth acrylic resin layer 53 and formed from a polycarbonate-base resin. A light transmissive design layer 32 is arranged so as to transmit visible light in a prescribed area of the design layer.

Description

Decorative film for insert molding, method for manufacturing decorative film for insert molding, and method for manufacturing resin molded products

The present invention relates to a decorative film for insert molding, a method for manufacturing a decorative film for insert molding, and a method for manufacturing a resin molded product, and in particular, for insert molding having a gravure-printed pattern for decoration through which visible light is transmitted. The present invention relates to a decorative film, a method for manufacturing a decorative film for insert molding, and a method for manufacturing a resin molded product.

As described in Patent Document 1 (Japanese Unexamined Patent Publication No. 2008-80570), for example, PMMA (methyl methacrylate resin; poly) on which a design for decoration is printed on a conventional decorative film for insert molding. Methylmethacrylate) Some films have a film placed on the surface. Further, in the conventional decorative film for insert molding, a backer layer made of an ABS resin may be integrated with the PMMA film in order to retain its shape in the PMMA film described above.

Japanese Unexamined Patent Publication No. 2008-80570

When a pattern is printed on a PMMA film by gravure printing, the film expands and contracts in the drying process of gravure printing. In particular, when the design layer and the light transmission pattern layer that transmits visible light according to the position of the design layer are formed by gravure printing, the expansion and contraction of the PMMA film generated in the drying step of gravure printing causes the design layer to be formed. The dimensional accuracy with respect to the light transmission pattern layer deteriorates.
Further, when a decorative film for insert molding having a backer layer made of ABS resin is used for manufacturing a resin molded product made of polycarbonate, the backer layer made of ABS resin having low heat resistance causes heat during injection molding. The effect of pressure on the gravure print layer cannot be sufficiently prevented. Therefore, in the decorative film for insert molding having a backer layer made of ABS resin, the ink flow of the gravure ink in the gravure printing layer is generated.

An object of the present invention is a decorative film for insert molding, which has high dimensional accuracy regarding a design layer and a light transmission pattern layer for gravure printing, and suppresses the generation of ink flow in gravure printing during the production of a resin molded product made of polycarbonate. Is to provide.

Hereinafter, a plurality of aspects will be described as means for solving the problem. These aspects can be arbitrarily combined as needed.
The decorative film for insert molding according to the appearance of the present invention is a decorative film for insert molding, which is a film that is three-dimensionally molded before insert molding. The decorative film for insert molding includes a multilayer film, a gravure printing layer, a first backer film, a second backer film, and a light transmission pattern layer. The multilayer film has a first main surface and a second main surface, and a first polycarbonate resin layer made of a polycarbonate resin is arranged between a first acrylic resin layer made of an acrylic resin and a second acrylic resin layer. ing. The multilayer film transmits visible light. The gravure printing layer is arranged on the side of the first main surface of the multilayer film, and has a symbol layer on which a symbol for gravure printing is formed. The first backer film is arranged on the opposite side of the multilayer film with the gravure printing layer interposed therebetween, and is made of an ABS-based resin that transmits visible light. The first backer film transmits visible light. The second backer film is arranged on the opposite side of the multilayer film with the first backer film interposed therebetween, and is a second polycarbonate resin made of a polycarbonate resin between a third acrylic resin layer made of an acrylic resin and a fourth acrylic resin layer. Layers are arranged. The second backer film transmits visible light. The light transmission pattern layer has a light transmission pattern that transmits visible light. The light transmission pattern of the light transmission pattern layer is arranged so that visible light passes through a predetermined portion of the design of the design layer.
In the decorative film for insert molding having such a configuration, in the multilayer film, the first polycarbonate resin layer is arranged between the first acrylic resin layer and the second acrylic resin layer, and the second backer film is the third acrylic resin layer. A second polycarbonate resin layer is arranged between the fourth acrylic resin layer and the fourth acrylic resin layer. The multilayer structure of the multilayer film suppresses shrinkage during printing and drying when forming the gravure print layer, and the multilayer structure of the multilayer film and the second backer film suppresses shrinkage during thermal laminating. The dimensional accuracy of the transparent pattern layer and the gravure printing pattern layer is improved. Further, the multilayer structure of the second backer film improves the heat resistance of the second backer film and suppresses the generation of ink flow in gravure printing during the production of the resin molded product made of polycarbonate. Further, the ABS resin of the first backer film reduces heat damage to the gravure ink.
In addition, in this specification, made of polycarbonate means that it is made by using a polycarbonate resin as a material for injection molding.

The above-mentioned decorative film for insert molding may be composed of a first polycarbonate resin layer and a second polycarbonate resin layer with a polycarbonate resin having a glass transition point of 120 ° C. or higher and 200 ° C. or lower. The decorative film for insert molding configured in this way can sufficiently improve the heat resistance of the multilayer film and the second backer film.
In the above-mentioned decorative film for insert molding, the specific heat of the first backer film is 1.3 × 10 ³ J / (kg · K) or more and 1.7 × 10 ³ J / (kg · K) or less. It may be configured. The decorative film for insert molding configured in this way has a high specific heat of the first backer film, and can reduce heat damage to the gravure ink.
The decorative film for insert molding described above may have a structure in which the light transmission pattern layer is included in the gravure printing layer. The decorative film for insert molding configured in this way can improve the dimensional accuracy of the light transmission pattern layer of the gravure printing layer.
The decorative film for insert molding described above may have a structure in which the light transmission pattern layer is formed on the second backer film. The decorative film for insert molding configured in this way can prevent the light transmission pattern layer from being affected by the heat laminating, and can further improve the dimensional accuracy of the light transmission pattern layer.

The method for producing a decorative film for insert molding according to a seemingly present invention is a method for producing a decorative film for insert molding, which is a film that is three-dimensionally molded before insert molding. In this method for producing a decorative film for insert molding, a first polycarbonate resin layer made of a polycarbonate resin is arranged between a first acrylic resin layer made of an acrylic resin and a second acrylic resin layer, and a first polycarbonate resin layer made of a polycarbonate resin is transmitted. From the first step of forming a gravure print layer by gravure printing on the side of the first main surface of the multilayer film, and from the first backer film and acrylic resin which are made of an ABS-based resin that transmits visible light and that transmit visible light. A second backer film made of a polycarbonate resin is arranged between the third acrylic resin layer and the fourth acrylic resin layer, and a gravure printing layer is formed on the second backer film that transmits visible light. It comprises a second step of heat laminating the film. In the second step of the method for producing the decorative film for insert molding, the release film comes into contact with the first contact heating body, the release film comes into contact with the second backer film, and the second backer film comes into contact with the first backer film. The peeling film, the second backer film, and the first backer film are brought into contact with each other by the heat given from the first contact heating body in a state where the multilayer film having the gravure printing layer formed on the first backer film is in contact with the first backer film. Thermally laminate with the multilayer film. The peeling strength of the release film from the first contact heating body when heat-laminated is the first of the second backer film when the second backer film is brought into direct contact with the first contact heating body and heat-laminated. It is characterized in that it is smaller than the peel strength from the contact heating body.
In the method for manufacturing a decorative film for insert molding configured as described above, in the second step, the release film comes into contact with the first contact heating body, and the release film comes into contact with the second backer film. 2 It is possible to prevent the backer film from coming into direct contact with the first contact heating element. Therefore, when the decorative film for insert molding is separated from the first contact heating body by heat laminating, the decorative film for insert molding is the first as compared with the case where the second backer film comes into direct contact with the first contact heating body. 1 The force pulled by the contact heating body weakens. As a result, it is possible to suppress the occurrence of pattern distortion in the gravure printing layer due to the force of the decorative film for insert molding being pulled by the first contact heating body.

The second step of the above-mentioned method for producing a decorative film for insert molding may be configured to include a first heat laminating step and a second heat laminating step. In the first heat laminating step, the first backer film and the second backer film are heat-laminated in a state where the first backer film is in contact with the second contact heating body and the second backer film is in contact with the first backer film. To form a multi-layer backer film. In the second thermal laminating step, the peeling film comes into contact with the first contact heating body, the second backer film of the multi-layer backer film comes into contact with the peeling film, and gravure printing is performed on the first backer film of the multi-layer backer film. In a state where the multilayer films on which the layers are formed are in contact with each other, the release film, the multilayer backer film, and the multilayer film are thermally laminated by the heat given from the first contact heater. In the method for manufacturing a decorative film for insert molding configured in this way, the number of rolls required for the laminator can be reduced.
In the above-mentioned method for manufacturing a decorative film for insert molding, in the first step, heat treatment is performed at a temperature higher than the evaporation temperature of the solvent of the gravure ink for forming the gravure printing layer after printing the gravure printing layer. May be done. In the method for producing a decorative film for insert molding configured as described above, the residual solvent can be reduced and foaming during forming can be suppressed.

The method for manufacturing a resin molded product according to the seemingly present aspect of the present invention includes a forming step of three-dimensionally molding the above-mentioned decorative film for insert molding and the addition of the insert molding to which a three-dimensional shape is imparted in the forming step. The insert molding is performed by a trimming step of trimming and removing an unnecessary part of the decorative film, and by setting the decorative film for insert molding in a mold and injecting a polycarbonate resin into the mold. It includes an injection molding step of molding a resin molded product made of polycarbonate which is decorated with a decorative film and transmits visible light.
In the method for manufacturing a resin molded product configured in this way, the heat resistance of the first backer film and the second backer film is improved by the multilayer structure of the second backer film, and the resin molded product made of polycarbonate that transmits visible light is transmitted. The generation of ink flow in the gravure print layer is suppressed during the production of the gravure print layer. The ABS resin of the first backer film can reduce the heat damage of the gravure printing layer to the gravure ink.

The decorative film for insert molding according to the present invention can realize high dimensional accuracy regarding the pattern layer and the light transmission pattern layer of gravure printing as compared with the conventional case, and can realize the ink flow of gravure printing at the time of manufacturing a resin molded product made of polycarbonate. The occurrence can be suppressed. The method for producing a decorative film for insert molding according to the present invention is a production method suitable for producing a decorative film for insert molding according to the present invention. Further, the method for manufacturing a resin molded product according to the present invention is a manufacturing method suitable for manufacturing a resin molded product using the decorative film for insert molding according to the present invention.

It is a front view of the door of the automobile to which the decorative film for insert molding of 1st Embodiment was applied. It is a front view of the door of the automobile to which the decorative film for insert molding of 1st Embodiment was applied. It is a schematic cross-sectional view which shows the state which the decorative film for insert molding is heated for forming. It is a schematic cross-sectional view which shows the state which the decorative film for insert molding is formed three-dimensionally. It is a schematic cross-sectional view which shows the state which the decorative film for insert molding is trimmed. It is a schematic cross-sectional view which shows the state which the decorative film for insert molding is set in a mold. It is a schematic cross-sectional view which shows the state which the molten resin is injected into the mold which set the decorative film for insert molding. It is a schematic cross-sectional view which shows the state which the resin molded article integrated with the decorative film for insert molding is taken out from a mold. It is a schematic cross-sectional view which shows an example of the structure of the decorative film for insert molding of 1st Embodiment. It is a schematic cross-sectional view which shows an example of the structure of the multilayer film on which the gravure printing layer was printed. It is a schematic sectional drawing for demonstrating the 1st thermal laminating step of thermal laminating a 1st backer film and a 2nd backer film. It is a schematic cross-sectional view for demonstrating the 2nd thermal laminating step of thermal laminating the whole decorative film for insert molding. It is a schematic cross-sectional view which shows the laminated body of the decorative film for insert molding and PET film immediately after thermal laminating. FIG. 6 is a schematic cross-sectional view showing another example of the configuration of a multilayer film on which a gravure print layer is printed. FIG. 6 is a schematic cross-sectional view showing another example of the configuration of a multilayer film on which a gravure print layer is printed. It is a schematic cross-sectional view which shows an example of the structure of the decorative film for insert molding of 2nd Embodiment. It is a schematic cross-sectional view which shows an example of the structure of the multilayer film on which the gravure printing layer was printed. It is a schematic cross-sectional view for demonstrating the 2nd thermal laminating step of thermal laminating the whole decorative film for insert molding. It is a schematic cross-sectional view which shows the member of the decorative film for insert molding immediately after thermal laminating, and the laminated body of PET film. It is a schematic diagram which shows the step of cutting the member of the decorative film for insert molding. FIG. 6 is a schematic cross-sectional view showing another example of the configuration of a multilayer film on which a gravure print layer is printed. FIG. 6 is a schematic cross-sectional view showing another example of the configuration of a multilayer film on which a gravure print layer is printed.

<First Embodiment>
(1) Application of Decorative Film for Insert Molding FIGS. 1A and 1B show a door 100 of an automobile to which the decorative film for insert molding is applied. As can be seen by comparing FIGS. 1A and 1B, the door 100 is configured so that the pattern 120 of the three lines can be displayed by visible light on the portion of the door trim 110 inside the door 100. The door trim 110 is a resin molded product decorated with a decorative film for insert molding. On the back side of the door trim 110 provided with the pattern 120, for example, a lighting device (not shown) such as an LED whose on / off is controlled by an automobile system (not shown) is arranged. The portion of the door trim 110 on which the pattern 120 is formed is manufactured by, for example, injection molding a polycarbonate resin. The pattern 120 of the door 100 is formed on the door trim 110 by the decorative film for insert molding described later.

(2) Method for manufacturing a resin molded product using a decorative film for insert molding FIGS. 2 to 7 show an outline of a method for manufacturing a resin molded product using a decorative film for insert molding 10. The decorative film 10 for insert molding is a film that is three-dimensionally molded and used before insert molding. For example, when decorating the door trim 110, the insert molding decorative film 10 is formed to match the three-dimensional shape of the door trim 110 and then inserted during injection molding of the door trim 110.
As shown in FIGS. 2 and 3, the forming step is a step of three-dimensionally molding the decorative film 10 for insert molding. As shown in FIG. 2, the decorative film 10 for insert molding is set in the mold 200. The decorative film 10 for insert molding is heated by the heat source 210 and softened. The arrow shown in FIG. 2 indicates the heat applied to the insert molding decorative film 10. Then, as shown in FIG. 3, the decorative film 10 for insert molding is formed into a product shape along the mold 200 by, for example, vacuum forming or compressed air forming. The arrows shown in FIG. 3 indicate the direction of the force applied to the insert molding decorative film 10 by vacuum forming or compressed air forming.

As shown in FIG. 4, the trimming step is a step of trimming and removing an unnecessary portion of the decorative film 10 for insert molding, which has been given a three-dimensional shape by the forming step. For trimming, for example, a die-cutting machine or a laser is used. Shown in FIG. 4 is a die 220 of a die-cutting machine.
An example of the injection molding process is shown in FIGS. 5 to 7. In the injection molding step, the decorative film 10 for insert molding was set in the mold 230, and the polycarbonate resin was injected into the mold 230 to decorate the decorative film 10 for insert molding. This is a step of molding a resin molded product 90 made of polycarbonate. FIG. 5 shows a state in which the three-dimensionally formed decorative film 10 for insert molding is set in the mold 230 that has been opened. The decorative film 10 for insert molding shown in FIG. 5 is set in the mold 230 by the robot arm 240. The arrow in FIG. 5 indicates the moving direction of the decorative film 10 for insert molding.

FIG. 6 shows a state in which the molten resin 290 in which the polycarbonate-based resin is heated and melted is injected into the cavity 235 of the mold-clamped mold 230. The general molding temperature (temperature of the molten resin 290) of the resin molded product 90 containing the polycarbonate-based resin is 260 ° C to 320 ° C. The decorative film 10 for insert molding of the first embodiment can be molded at a molding temperature of 300 ° C. or higher. The arrow in FIG. 6 indicates the movement of the movable mold of the mold 230 at the time of mold clamping. FIG. 7 shows that the mold 230 is opened and the resin molded product 90 made of a polycarbonate-based resin is taken out.
When the mold 230 is opened, the robot arm 240 enters and the resin molded product 90 is taken out of the mold 230. The arrow shown in the mold 230 in FIG. 7 indicates the moving direction of the movable mold. The arrows shown around the robot arm 240 and the resin molded product 90 indicate the moving direction of the resin molded product 90. An example of this resin molded product 90 is the door trim 110 described above.

(3) Configuration of Decorative Film 10 for Insert Molding As shown in FIG. 8, the decorative film 10 for insert molding includes a multilayer film 20, a gravure printing layer 30, a first backer film 40, and a first. It is provided with 2 backer films 50. The first figure 36 formed on the design layer 31 of the gravure printing layer 30 is arranged at a predetermined position of the door trim 110 which is a resin molded product having a three-dimensional shape. The light transmission pattern 37 of the light transmission pattern layer 32 is arranged so that visible light Li transmits around the first figure 36 or the first figure 36. In other words, the light transmission pattern 37 is arranged so that visible light passes through a predetermined portion of the symbol of the symbol layer 31. The light transmission pattern 37 is a pattern of the light transmission portion 32a described later. The deviation between the first figure 36 and the light transmission pattern 37 is preferably ± 0.6 mm or less.
(3-1) Multilayer film 20
The multilayer film 20 has a first main surface 20a and a second main surface 20b. The multilayer film 20 transmits visible light. The thickness of the multilayer film 20 is, for example, 30 μm to 150 μm. The multilayer film 20 having a thickness of 30 μm to 150 μm is suitable for gravure printing. In this first embodiment, the thickness of the multilayer film 20 is set to, for example, 50 μm. In the multilayer film 20, the first polycarbonate resin layer 22 is arranged between the first acrylic resin layer 21 and the second acrylic resin layer 23. The exposed surface of the first acrylic resin layer 21 is the first main surface 20a, and the exposed surface of the second acrylic resin layer 23 is the second main surface 20b.
The first acrylic resin layer 21 and the second acrylic resin layer 23 are made of an acrylic resin. Examples of the acrylic resin used for the first acrylic resin layer 21 and the second acrylic resin layer 23 include PMMA. In the present invention, when the first acrylic resin layer 21 and the second acrylic resin layer 23 are made of an acrylic resin, not only when these layers are composed of only the acrylic resin but also the acrylic resin. It also includes the case where an additive is added.
The first polycarbonate resin layer 22 is made of a polycarbonate resin. As the polycarbonate resin used for the first polycarbonate resin layer 22, for example, there is a polycarbonate resin. In the present invention, when the first polycarbonate resin layer 22 is made of a polycarbonate resin, not only when this layer is composed of only the polycarbonate resin but also when an additive is added to the polycarbonate resin. Is also included. The thickness of the first polycarbonate resin layer 22 must be smaller than the thickness of the multilayer film 20 in order to suppress the shrinkage rate during gravure printing, but is preferably 10 μm to 105 μm. The glass transition point (Tg) of the first polycarbonate resin layer 22 is, for example, 120 ° C to 200 ° C. In order to obtain high heat resistance, a high glass transition point (Tg) is preferable, the temperature is preferably 150 ° C to 200 ° C, and even more preferably 170 ° C to 200 ° C. The glass transition point (Tg) is measured according to JIS7121.
The multilayer film 20 preferably has a shrinkage rate during gravure printing within the range of −0.20% to +0.20% in both the feed direction and the width direction of the multilayer film 20. It is more preferable that the shrinkage rate is suppressed in the range of −0.15% to + 0.15%.

(3-2) Gravure printing layer 30
The gravure printing layer 30 is arranged on the side of the first main surface 20a of the multilayer film 20. More specifically, the gravure printing layer 30 is formed by being printed on the first main surface 20a (exposed surface of the first acrylic resin layer 21) of the multilayer film 20. The gravure printing layer 30 has a pattern layer 31, a light transmitting pattern layer 32, and an adhesive layer 33. The design layer 31 and the light transmission pattern layer 32 are formed by using conventional gravure ink. The gravure ink contains a binder resin, a solvent, and a colorant. Examples of the binder resin include vinyl chloride vinyl acetate copolymer resin, acrylic resin, polyester resin and polyurethane resin. The solvent is for dissolving the resin and is selected according to the resin. Solvents for gravure inks include, for example, toluene, methyl ethyl ketone, ethyl acetate and isopropyl alcohol.
In the light transmission pattern layer 32, a shielding portion 32b that blocks visible light is formed by gravure printing, and a portion where the shielding portion 32b is not printed becomes a light transmission portion 32a.
The light transmission pattern layer 32 is aligned with the design layer 31 at the time of printing. By such alignment, visible light transmitted through the light transmission pattern layer 32 can pass through a predetermined portion of the design layer 31. As shown in FIG. 1B, the pattern 120 through which visible light is transmitted is arranged at a predetermined place to be decorated such as a door 100, so that high dimensional accuracy is required. The adhesive layer 33 is a layer for adhering to the first backer film 40. The adhesive layer 33 is a layer that transmits visible light. As the adhesive constituting the adhesive layer 33, for example, vinyl chloride vinyl acetate copolymer resin, acrylic resin, polyester resin and polyurethane resin are used.

(3-3) First backer film 40 and second backer film 50
The multi-layer backer film is formed by the thermal laminating of the first backer film 40 and the second backer film 50.
The first backer film 40 is made of an ABS-based resin that transmits visible light. ABS-based resins that transmit visible light include, for example, ABS resins that transmit visible light and MABS (methylmethacrylate, acrylonitrile, butadiene, styrene) resins that transmit visible light. In the present invention, when the first backer film 40 is made of an ABS-based resin that transmits visible light, not only when this film is composed of only the ABS-based resin, but also an additive is added to the ABS-based resin. It is also included if it is.
The specific heat of the first backer film 40 is 1.3 × 10 ³ J / (kg · K) or more and 1.7 × 10 ³ J / (kg · K) or less. The specific heat measurement method is based on JIS K 7123. It is preferable that the first backer film 40 has a high specific heat because the temperature rise of the gravure printing layer 30 can be suppressed. If the specific heat is too high, it becomes difficult for the material to warm and soften, and there is a possibility that the adhesion between the layers cannot be ensured.
The thickness of the first backer film 40 is, for example, 100 μm to 250 μm. The thickness of the first backer film 40 is preferably 150 μm to 250 μm, more preferably 200 μm to 250 μm, because the thicker the thickness, the more the heat damage can be reduced.

The second backer film 50 is arranged on the opposite side of the multilayer film 20 with the first backer film 40 interposed therebetween. The thickness of the second backer film 50 is, for example, 200 μm to 500 μm. In the second backer film 50, the second polycarbonate resin layer 52 is arranged between the third acrylic resin layer 51 and the fourth acrylic resin layer 53. The third acrylic resin layer 51 and the fourth acrylic resin layer 53 are made of an acrylic resin. Examples of the acrylic resin used for the third acrylic resin layer 51 and the fourth acrylic resin layer 53 include PMMA. In the present invention, when the third acrylic resin layer 51 and the fourth acrylic resin layer 53 are made of an acrylic resin, not only when these layers are composed of only the acrylic resin but also the acrylic resin. It also includes the case where an additive is added.
The second polycarbonate resin layer 52 is made of a polycarbonate resin. As the polycarbonate resin used for the second polycarbonate resin layer 52, for example, there is a polycarbonate resin. In the present invention, when the second polycarbonate resin layer 52 is made of a polycarbonate resin, not only when this layer is composed of only the polycarbonate resin but also when an additive is added to the polycarbonate resin. Is also included. The thickness of the second polycarbonate resin layer 52 must be smaller than the thickness of the second backer film 50, and is, for example, 70 μm to 350 μm. The thickness of the second polycarbonate resin layer 52 is preferably 105 μm to 280 μm, more preferably 140 μm to 210 μm, in order to achieve both heat resistance and shapeability. The glass transition point (Tg) of the first polycarbonate resin layer 22 is, for example, 120 ° C to 200 ° C. In order to obtain high heat resistance, a high glass transition point (Tg) is preferable, the temperature is preferably 150 ° C to 200 ° C, and even more preferably 170 ° C to 200 ° C.

(4) Method for Manufacturing Decorative Film 10 for Insert Molding of the First Embodiment An example of the method for manufacturing the decorative film 10 for insert molding is shown in FIGS. 9 to 12. 9 and 10 show a partial cross section of a long sheet. First, as shown in FIG. 9, in the first step, the gravure printing layer 30 is formed by gravure printing on the side of the first main surface 20a of the multilayer film 20. First, the design layer 31 is printed on the multilayer film 20 by gravure printing. Next, the position is aligned with the design layer 31, and the shielding portion 32b is printed by gravure printing to form a light transmission pattern layer 32 that transmits visible light at a predetermined position of the design layer 31. In other words, the light transmitting portion 32a of the light transmitting pattern layer 32 is formed at a predetermined position of the design layer 31. Further, an adhesive is printed on the light transmission pattern layer 32 by gravure printing to form the adhesive layer 33.
In the first step, after printing the gravure printing layer 30, heat treatment is performed at a temperature higher than the evaporation temperature of the solvent of the gravure ink for forming the gravure printing layer 30. By this heat treatment, the residual solvent of the gravure ink is reduced as compared with that before the heat treatment.
The second step includes a first thermal laminating step shown in FIG. 10 and a second thermal laminating step shown in FIG.
In the first heat laminating step, the first backer film 40 is brought into contact with the heating drum 420, which is the second contact heating body, and the second backer film 50 is brought into contact with the first backer film 40. The 40 and the second backer film 50 are thermally laminated to form a multi-layer backer film 60 (see FIG. 11). The temperature of the heating drum 420 is, for example, 170 ° C. Heat is transferred from the heating drum 420 to the second backer film 50 via the first backer film 40. In the first heat laminating step, since the first backer film 40 is in contact with the heating drum 420, the first backer film 40 is not strongly attracted to the heating drum 420 by the heat laminating.

In the second thermal laminating step, the PET film 80, which is a release film, the multi-layer backer film 60, and the multilayer film 20 are thermally laminated by the heat given from the heating drum 410, which is the first contact heating body. The temperature of the heating drum 410 is, for example, 170 ° C. The PET film 80 was brought into contact with the heating drum 410, the second backer film 50 of the multilayer backer film 60 was brought into contact with the PET film, and the gravure printing layer 30 was formed on the first backer film 40 of the multilayer backer film 60. Thermal laminating is performed with the multilayer film 20 in contact with each other. The thickness of the PET film 80 is, for example, 38 μm to 75 μm. PET is an abbreviation for polyethylene terephthalate.
The same drum may be used for the heating drum 410 and the heating drum 420. Further, here, the heating drum 410 was used for the first contact heating body and the heating drum 420 was used for the second contact heating body, but those that can be used for the first contact heating body and the second contact heating body are the heating drums. Not limited to. The first contact heating body and the second contact heating body may be any as long as they can apply heat and pressure to the film to be laminated in contact with each other.
Although the PET film 80 is used as the peeling film, a film other than the PET film 80 may be used. As the peeling film, a film of the same type other than the PET film 80 can be used. As the release film, for example, a polyethylene naphthalate (PEN) film can be used. The peeling strength of the peeling film from the heating drum 410 when heat-laminated is such that the peeling strength of the second backer film 50 from the heating drum 410 when the second backer film 50 is directly contacted with the heating drum 410 and heat-laminated. It may be smaller than the strength.
As shown in FIG. 12, immediately after the thermal laminating, the PET film 80 is laminated on the insert molding decorative film 10. By peeling the PET film 80 from the laminated body in the state of FIG. 12, the decorative film 10 for insert molding can be obtained.
<Second Embodiment>

(5) Application of Decorative Film for Insert Molding The decorative film for insert molding of the second embodiment is also applied to, for example, the door 100 of an automobile, like the decorative film for insert molding of the first embodiment.
(6) Method for Manufacturing Resin Molded Product Using Decorative Film for Insert Molding The resin molded product using the decorative film for insert molding according to the second embodiment is also the same as that of the first embodiment, for example, FIGS. 2 to 2. It can be manufactured by the manufacturing method of the resin molded product shown in 7.

(7) Configuration of Decorative Film 10 for Insert Molding As shown in FIG. 15, the decorative film 10 for insert molding includes a multilayer film 20, a gravure printing layer 30, a first backer film 40, and a first backer film 40. 2 The backer film 50 and the screen printing layer 70 are provided. Also in the decorative film 10 for insert molding of the second embodiment, the first figure 36 formed on the design layer 31 of the gravure printing layer 30 is arranged at a predetermined position of the door trim 110 which is a resin molded product having a three-dimensional shape. To. The light transmission pattern 77 of the light transmission pattern layer 71 is arranged so that visible light Li transmits around the first figure 36 or the first figure 36. In other words, the light transmission pattern 77 is arranged so that visible light passes through a predetermined portion of the symbol of the symbol layer 31. The light transmission pattern 77 is a pattern of the light transmission portion 71a described later. The deviation between the first figure 36 and the light transmission pattern 77 is preferably ± 5 mm or less.
(7-1) Multilayer film 20
The multilayer film 20 of the second embodiment has the same configuration as the multilayer film 20 of the first embodiment. Therefore, the description of the configuration of the multilayer film 20 of the second embodiment is omitted here.
(7-2) Gravure printing layer 30
The gravure printing layer 30 of the second embodiment is also arranged on the side of the first main surface 20a of the multilayer film 20. More specifically, the gravure printing layer 30 is formed by being printed on the first main surface 20a (exposed surface of the first acrylic resin layer 21) of the multilayer film 20. The gravure printing layer 30 has a design layer 31 and an adhesive layer 33. The gravure printing layer 30 of the second embodiment does not have the light transmission pattern layer 32 as compared with the gravure printing layer 30 of the first embodiment. In the gravure printing layer 30 of the second embodiment, the design layer 31 and the adhesive layer 33 are adjacent to each other. In other words, after the design layer 31 is formed on the multilayer film 20, the adhesive layer 33 is printed on the design layer 31. Since the symbol layer 31 and the adhesive layer 33 of the second embodiment are the same as the symbol layer 31 and the adhesive layer 33 of the first embodiment, the symbol layer 31 and the adhesive layer 33 of the second embodiment will be described here. Is omitted.
(7-3) First backer film 40 and second backer film 50
The decorative film 10 for insert molding of the second embodiment also has a multi-layer backer film 60 (see FIG. 17) composed of a thermal laminate of the first backer film 40 and the second backer film 50. Since the multi-layer backer film 60 composed of the first backer film 40 and the second backer film 50 of the second embodiment is the same as the multi-layer backer film 60 of the first embodiment, the multi-layer of the second embodiment is the same. The description of the backer film 60 will be omitted.

(8) Method for manufacturing decorative film 10 for insert molding according to the second embodiment An example of the method for manufacturing the decorative film 10 for insert molding according to the second embodiment is shown in FIGS. 16 to 19. 16 and 1 show a cross section of a portion of a long sheet. First, as shown in FIG. 16, in the first step, the gravure printing layer 30 is formed by gravure printing on the side of the first main surface 20a of the multilayer film 20. First, the design layer 31 is printed on the multilayer film 20 by gravure printing. Next, the adhesive is printed on the design layer 31 by gravure printing to form the adhesive layer 33.
In the first step, after printing the gravure printing layer 30, heat treatment is performed at a temperature higher than the evaporation temperature of the solvent of the gravure ink for forming the gravure printing layer 30. By this heat treatment, the residual solvent of the gravure ink is reduced as compared with that before the heat treatment.
In the second step, also in the method for manufacturing the decorative film 10 for insert molding of the second embodiment, the first thermal laminating step shown in FIG. 10 and the second thermal laminating step shown in FIG. 17 are included. included.
In the first heat laminating step, the first backer film 40 comes into contact with the heating drum 420 which is the second contact heating body, and the second backer film 50 comes into contact with the first backer film 40. In this state, the first backer film 40 and the second backer film 50 are thermally laminated to form a multi-layer backer film 60 (see FIG. 17). The temperature of the heating drum 420 is, for example, 170 ° C.

As shown in FIG. 17, in the second heat laminating step of the second embodiment as well as the second laminating step of the first embodiment, the heat given from the heating drum 410 which is the first contact heating body is used. The PET film 80, which is a release film, the multi-layer backer film 60, and the multilayer film 20 are thermally laminated. The second thermal laminating step of the second embodiment is carried out in the same manner as the second laminating step of the first embodiment except that the configuration of the gravure printing layer 30 is different, and thus the description thereof will be omitted here.
As shown in FIG. 18, immediately after the thermal laminating, the PET film 80 is laminated on the member 11 of the decorative film for insert molding. FIG. 18 shows a cross-sectional structure of a member 11 of a decorative film for insert molding, and the member 11 immediately after thermal laminating is in a state similar to the roll 500 shown in FIG. There is. In the next step, as shown in FIG. 19, the single-wafer sheet 510 of the member 11 is created from the roll 500 of the member 11. For example, slitting or cutting is used to prepare the sheet-fed sheet 510. In other words, the long member 11 of the roll 500 is cut into a short single-wafer sheet 510 having a predetermined length. At the time of producing the single-wafer sheet 510, the PET film 80 is in a state of being laminated on the member 11.
In the next screen printing step, the screen printing layer 70 is formed on the second backer film 50 of the member 11 of the sheet-fed sheet from which the PET film 80 has been peeled off. First, the PET film 80 is peeled off from the member 11 of the single-wafer sheet. Next, the light transmission pattern layer 71 is printed on the second backer film 50 by screen printing using a conventional ink for screen printing. In the light transmission pattern layer 71, a shielding portion 71b that blocks visible light is formed by screen printing, and a portion where the shielding portion 71b is not printed becomes a light transmission portion 71a. At the time of printing the light transmission pattern layer 71, the pattern of the light transmission pattern layer 71 and the design layer 31 are aligned with each other. Further, the adhesive layer 72 is printed on the light transmission pattern layer 71 by screen printing. Materials used for forming the adhesive layer 72 include, for example, vinyl chloride vinyl acetate copolymer resin, polyester resin, and acrylic resin.

(9) Modification example (9-1) Modification example A
In the first embodiment and the second embodiment, the case where the surface (second main surface 20b) of the multilayer film 20 is exposed has been described. However, a surface layer may be formed on the second main surface 20b of the multilayer film 20. For example, as shown in FIGS. 13 and 14, and FIGS. 20 and 21, even if the second main surface 20b of the multilayer film 20 is provided with

mat layers

24 and 25 that transmit visible light as a surface layer. good. An opening may be provided in the mat layers 24 and 25 to transmit visible light.
The mat layer 24 has a maximum height roughness (Rz) (measured according to JISB0601) of surface irregularities smaller than 20 μm, and mainly visually expresses irregularities. On the other hand, the mat layer 25 has a maximum height roughness (Rz) (measured according to JISB0601) of 20 μm or more on the surface unevenness, and the unevenness is perceived not only visually but also by touch. It is something that makes you.
Instead of the mat layers 24 and 25, another pattern layer may be formed on the second main surface 2b of the multilayer film 20 by gravure printing. At this time, the gravure printing layer formed on the second main surface 2b of the multilayer film 20 is preferably formed at the same time as the gravure printing layer 30 formed on the first main surface 2a. Further, the second figure of the design layer formed on the second main surface 2b of the multilayer film 20 is arranged with reference to the first figure 36 of the design layer 31 of the gravure printing layer 30 formed on the first main surface 2a. Is preferable.

(9-2) Modification B
In the first embodiment and the second embodiment, in the production of the decorative film 10 for insert molding, the second step is a first thermal laminating step (see FIG. 10) and a second thermal laminating step (FIG. 11 or FIG. 17) has been described.
However, when the delivery roll has four axes, in the second step, the PET film 80 comes into contact with the heating drum 410, the PET film 80 comes into contact with the second backer film 50, and the second backer film 50 comes into contact with the PET film 80. 2 The PET film 80 is generated by the heat given from the heating drum 410 in a state where the first backer film 40 is in contact with the backer film 50 and the multilayer film 20 on which the gravure printing layer 30 is formed is in contact with the first backer film 40. And the second backer film 50, the first backer film 40, and the multilayer film 20 may be configured to be thermally laminated. The difference from the manufacturing method of the decorative film 10 for insert molding of the first embodiment is that the first backer film 40 and the second backer film 50 are hot-laminated until the second backer film 50 comes into contact with the PET film 80. Is the point where is in a separated state.

(9-3) Modification C
In the second embodiment, the case where the screen printing layer 70 is formed by screen printing after cutting into the sheet-fed sheet 510 has been described. However, screen printing for forming the screen printing layer may be performed by a roll-to-roll method. Also in the case of the roll-to-roll method, the light transmission pattern layer 71 is printed on the second backer film 50 from which the PET film 80 has been peeled off by screen printing. Further, in the roll-to-roll method, the adhesive layer 72 is printed on the light transmission pattern layer 71 by screen printing.

(10) Features (10-1)
In the above-mentioned decorative film 10 for insert molding, the multilayer film 20 has the first polycarbonate resin layer 22 arranged between the first acrylic resin layer 21 and the second acrylic resin layer 23, and the second backer film 50 has the third acrylic. The second polycarbonate resin layer 52 is arranged between the resin layer 51 and the fourth acrylic resin layer 53. In the decorative film 10 for insert molding, the multilayer structure of the multilayer film 20 and the second backer film 50 suppresses the shrinkage of the member during printing and drying when forming the gravure printing layer 30 to, for example, ± 0.15%. In addition, shrinkage of the member during thermal laminating is suppressed. As a result, the dimensional accuracy of the gravure printing pattern layer 31 and the light transmission pattern layer 32 or the dimensional accuracy of the gravure printing design layer 31 and the screen printing light transmission pattern layer 71 is improved. Further, the multi-layer structure of the second backer film 50 improves the heat resistance of the multi-layer backer film 60, and even if it comes into contact with the molten resin 290 that reaches around 300 ° C., for example, during the production of the polycarbonate resin molded product 90. In the decorative film 10 for insert molding, the generation of ink flow in gravure printing is suppressed. Further, in the insert molding decorative film 10, the ABS resin of the first backer film 40 can reduce heat damage to the gravure ink. Further, the strength of the insert molding decorative film 10 is improved by the second polycarbonate resin layer 52, and cracks are less likely to occur in the insert molding decorative film 10 during forming and molding.
Ink flow is a phenomenon in which the resin used for printing melts due to high temperature.

(10-2)
The glass transition point of the polycarbonate resin of the first polycarbonate resin layer 22 and the second polycarbonate resin layer 52 of the above-mentioned decorative film 10 for insert molding is 120 ° C. or higher and 200 ° C. or lower. Since the glass transition points of the polycarbonate-based resins of the first polycarbonate resin layer 22 and the second polycarbonate resin layer 52 are high, the heat resistance of the multilayer film 20 and the multilayer backer film 60 is improved. The gravure printing layer 30 sandwiched between the multilayer film 20 and the multilayer backer film 60 having improved heat resistance is a resin molded product 90 into which a molten resin 290 of a polycarbonate resin at around 300 ° C. is injected. Even if it is inserted in the production, the ink flow of the gravure printing layer 30 is less likely to occur.
(10-3)
The first backer film 40 of the above-mentioned decorative film 10 for insert molding is configured so that the specific heat is 1.3 × 103 J / (kg · K) or more and 1.7 × 103 J / (kg · K) or less. ing. By increasing the specific heat of the first backer film 40 in this way, it is possible to reduce the damage caused to the gravure printing layer due to the heat.
(10-4)
When the light transmission pattern layer 32 is included in the gravure printing layer 30, the decorative film 10 for insert molding of the first embodiment described above is a member of the member at the time of forming the gravure printing layer 30 and at the time of thermal laminating. Shrinkage is suppressed. As a result, the dimensional accuracy of the light transmission pattern layer 32 of the gravure printing layer 30 is improved.
(10-5)
In the above-mentioned decorative film for insert molding of the second embodiment, when the light transmission pattern layer 71 is formed on the second backer film 50, the light transmission pattern layer 71 is formed after heat laminating. As a result, the light transmission pattern layer 71 is prevented from being affected by the thermal laminating.

(10-6)
In the method for manufacturing the decorative film 10 for insert molding according to the first embodiment or the second embodiment described with reference to FIGS. 9 to 12 or 16 to 19, in the second step (see FIG. 11 or FIG. 17). Since the PET film 80, which is a release film, comes into contact with the heating drum 410, which is the first contact heating body, and the second backer film 50 comes into contact with the PET film 80, the second backer film 50 comes into direct contact with the heating drum 410. do not do. Therefore, when the decorative film 10 for insert molding is separated from the heating drum 410 by heat laminating, the decorative film 10 for insert molding is a heating drum as compared with the case where the second backer film 50 comes into direct contact with the heating drum 410. The force pulled by 410 weakens. As a result, it is possible to suppress the occurrence of pattern distortion in the gravure printing layer 30 due to the force of the decorative film 10 for insert molding being pulled by the heating drum 410.
(10-7)
The method for manufacturing the decorative film 10 for insert molding according to the first embodiment or the second embodiment described with reference to FIGS. 9 to 12 or 16 to 19 includes a first thermal laminating step (see FIG. 10). It is configured to include a second thermal laminating step (see FIG. 11 or FIG. 17). By separating the laminating steps, the number of feed rolls used in the laminator can be reduced. In this case, since the PET film 80 does not need to be used in the first thermal laminating step (see FIG. 10), it is not necessary to increase the PET film 80 even though the number of thermal laminating steps is increased.

(10-8)
In the method for manufacturing the decorative film 10 for insert molding described above, the first step includes heat treatment at a temperature higher than the evaporation temperature of the solvent of the gravure ink for forming the gravure printing layer 30 after printing the gravure printing layer 30. You may. When such a heat treatment is performed, the residual solvent in the gravure printing layer 30 can be reduced, and foaming during forming can be suppressed.
(10-9)
In the method for manufacturing the resin molded product 90 described with reference to FIGS. 2 to 7, the heat resistance of the first backer film 40 and the second backer film 50 (multi-layer backer film 60) due to the multilayer structure of the second backer film 50. Is improved. As a result, the generation of ink flow in the gravure printing layer 30 is suppressed during the production of the polycarbonate resin molded product 90 into which the molten resin 290 of the polycarbonate resin at around 300 ° C. is injected. Further, the ABS resin of the first backer film 40 can reduce heat damage to the gravure printing layer 30 gravure ink.
Although the first embodiment and the second embodiment of the present invention have been described above, the present invention is not limited to the first embodiment and the second embodiment, and various aspects are not deviated from the gist of the invention. It can be changed. In particular, the plurality of embodiments and modifications described herein can be arbitrarily combined as needed.

10 Decorative film for insert molding 20 Multilayer film 21 First acrylic resin layer 22 First polycarbonate resin layer 23 Second acrylic resin layer 30 Gravure printing layer 31 Design layer 32 Light transmission pattern layer 33 Adhesive layer 40 First backer film 50 2 Backer film 51 3rd acrylic resin layer 52 2nd polycarbonate resin layer 53 4th acrylic resin layer 60 Multi-layer backer film 70 Screen printing layer 71 Light transmission pattern 72 Adhesive layer 80 PET film (example of peeling film)
410 Heating drum (example of first contact heating element)
420 Heating drum (example of second contact heating element)

Claims

A decorative film for insert molding, which is a film that is three-dimensionally molded before insert molding.
It has a first main surface and a second main surface, and a first polycarbonate resin layer made of a polycarbonate resin is arranged between a first acrylic resin layer made of an acrylic resin and a second acrylic resin layer to emit visible light. A transparent multilayer film and
A gravure printing layer arranged on the side of the first main surface of the multilayer film, having a pattern layer on which a gravure printing pattern is formed, and transmitting visible light, and a gravure printing layer.
A first backer film, which is arranged on the opposite side of the multilayer film with the gravure printing layer interposed therebetween and is made of an ABS-based resin that transmits visible light and transmits visible light.
A second polycarbonate resin layer made of a polycarbonate resin is arranged between a third acrylic resin layer made of an acrylic resin and a fourth acrylic resin layer arranged on the opposite side of the multilayer film with the first backer film interposed therebetween. A second backer film that transmits visible light and a light transmitting pattern layer that has a light transmitting pattern that transmits visible light are provided.
A decorative film for insert molding, in which the light transmission pattern of the light transmission pattern layer is arranged so that visible light passes through a predetermined portion of the design of the design layer.
The glass transition point of the polycarbonate resin constituting the first polycarbonate resin layer and the second polycarbonate resin layer is 120 ° C. or higher and 200 ° C. or lower.
The decorative film for insert molding according to claim 1.
The specific heat of the first backer film is 1.3 × 10 3 J / (kg · K) or more and 1.7 × 10 3 J / (kg · K) or less.
The decorative film for insert molding according to claim 1 or 2.
The light transmission pattern layer is included in the gravure printing layer.
The decorative film for insert molding according to any one of claims 1 to 3.
The light transmission pattern layer is formed on the second backer film.
The decorative film for insert molding according to any one of claims 1 to 3.
A method for manufacturing a decorative film for insert molding, which is a film that is three-dimensionally molded before insert molding.
A first polycarbonate resin layer made of a polycarbonate resin is arranged between a first acrylic resin layer made of an acrylic resin and a second acrylic resin layer, and gravure is provided on the side of the first main surface of a multilayer film that transmits visible light. The first step of forming a gravure print layer that transmits visible light by printing,
A second polycarbonate resin layer made of a polycarbonate resin is arranged between a first backer film made of an ABS resin that transmits visible light, a third acrylic resin layer made of an acrylic resin, and a fourth acrylic resin layer. A second backer film that transmits visible light is provided with a second step of thermally laminating the multilayer film on which the gravure printing layer is formed.
In the second step, the release film comes into contact with the first contact heating body, the release film comes into contact with the second backer film, the second backer film comes into contact with the first backer film, and the above. The peeling film, the second backer film, and the first backer film are brought into contact with the first backer film by the heat given from the first contact heating body in a state where the multilayer film having the gravure printing layer formed is in contact with the first backer film. And the multilayer film are heat-laminated,
The peeling film has a peeling strength from the first contact heating body when heat-laminated, and the second backer film when the second backer film is brought into direct contact with the first contact heating body and heat-laminated. A method for producing a decorative film for insert molding, which is smaller than the peel strength from the first contact heating body.
The second step is
With the first backer film in contact with the second contact heating body and the second backer film in contact with the first backer film, the first backer film and the second backer film are thermally laminated and duplicated. The first thermal laminating step to form the layer backer film,
The peeling film is in contact with the first contact heating body, the second backer film of the multi-layer backer film is in contact with the peeling film, and the gravure is in contact with the first backer film of the multi-layer backer film. A second thermal laminate in which the release film, the multi-layer backer film, and the multilayer film are thermally laminated by the heat given from the first contact heating body in a state where the multilayer film on which the print layer is formed is in contact with each other. Including steps
The method for manufacturing a decorative film for insert molding according to claim 6.
In the first step, after printing the gravure printing layer, heat treatment is performed at a temperature higher than the evaporation temperature of the solvent of the gravure ink for forming the gravure printing layer.
The method for manufacturing a decorative film for insert molding according to claim 7.
The forming step of three-dimensionally molding the decorative film for insert molding according to any one of claims 1 to 5.
A trimming step of trimming and removing an unnecessary portion of the decorative film for insert molding, which has been given a three-dimensional shape in the forming step.
By setting the decorative film for insert molding in a mold and injecting a polycarbonate resin into the mold, the polycarbonate that is decorated by the decorative film for insert molding and transmits visible light is transmitted. A method for manufacturing a resin molded product, comprising an injection molding step for molding the resin molded product.